How do they do it?

[Malleus]

Does anyone have direct knowledge of how the brake systems are filled on the assembly lines? As many times as I've been in assembly plants, I never thought to ask. And the systems and methods for fillings non-sealed systems like engines, transmissions and differentials is different. I know that much.

 

[Toyo Boyo]

I visited the MINI production line in Oxford, UK a couple of times and watched this process……

The entire brake system is complete, not sure which part of the production line as it loops around.

A fitting is then attached to the brake reservoir and a powerful vacuum applied (not sure how strong a vacuum).

Once all the system is in vacuum a pre-determined volume of brake fluid is automatically added at this station. The vacuum basically ‘sucks’ the fluid right through the system. The fluid doesn’t contact the atmosphere which is a good thing. The filling mechanism is removed.

The reservoir cover is fitted, job done.

A benefit of this - if there are any leaks the system won’t achieve full vacuum so the fault can be fixed immediately.

 

[Malleus]

Ah, so. Any idea how they fill the ABS pump? It's a multivalve body, so not all of it is open to the system at any given time. Maybe there's a bypass or fill setting where all the valves are open?

 

[mudgudgeon]

I visited the MINI production line in Oxford, UK a couple of times and watched this process……

The entire brake system is complete, not sure which part of the production line as it loops around.

A fitting is then attached to the brake reservoir and a powerful vacuum applied (not sure how strong a vacuum).

Once all the system is in vacuum a pre-determined volume of brake fluid is automatically added at this station. The vacuum basically ‘sucks’ the fluid right through the system. The fluid doesn’t contact the atmosphere which is a good thing. The filling mechanism is removed.

The reservoir cover is fitted, job done.

A benefit of this - if there are any leaks the system won’t achieve full vacuum so the fault can be fixed immediately.

That's brilliant! Now someone needs to make an attachment for a HVAC pump